Thought I'd share my interesting repair with everyone today.
Gentleman brought me a UTV with a stripped drain plug. Only 1000 miles on the thing... No depth to retap threads larger and the engine case itself was in places only 1/8" so neither a helicoil nor timesert was going to work (the case is so thin which is why it stripped in the first place).
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The estimate to pull the motor is 9hrs. Plus replacing a case half made the estimated repair given at multiple places similar in price to an actual motor ($3500).
Here's what we ordered.
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After removing the plastic skid plate I found another 1/8" steel skid to contend with; that got cut out as well.
This motor has already sat for nearly a week at another repair shop with the plug out in order to drain the remaining oil out. Not good enough.
After cleaning and torching the AL around the plug hole in preparation for the weld in extension bung and trying to tack it in- oil still kept bubbling out of the pourous cast AL. (Put this on repeat for hours).
And upsidedown TIG welding dirty material sucks.
Ugly fusion tack weld
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Unacceptable- cut it off, clean it, try again...
At this point I made no further attempt to photograph this fix LoL
Upsidedown won't work so...
4- 40's on the ground and tip it on its side...
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Anyway, after much welding and cleaning and welding and grinding; I finally got the weld bung on with no more pin holes from bubbling oil. It actually looked pretty decent, but my vanity kept me from photos LoL.
Welded up the skid plate and added some 1 3/4" 0.120 DOM around the skid plate drain hole to extend the skid lower than the new plug.
And surprisingly between the two of us- we pushed it back on all 4 wheels and loaded it up.
A complicated fix. But when the 2 options are
1). A new motor
Or
2.) 9 hours to pull the motor and 9 hrs to replace it -after welding in position on the bench
This 4.5 hr fix was pretty good.
And with 4 times the thread depth than stock; it should be the least of his worries.
Cross your fingers and say a prayer for him that it doesn't leak
Thanks for watching.